You are on page 1of 6

Metal Forming - Hot Rolling

Understanding the Properties of Oxide Scales on Hot Rolled Steel Strip


P. Henk Bolt

Corus Research, Development & Technology, ljmuiden I The Netherlands

Surface quality and downstream processability of hot rolled strip depend on tertiary scale thickness and composition at all process stages,
from secondary descaling to the cold coil. TGA oxidation experiments provided the basis for quantitative modelling of scale growth during
finishing hot rolling of low carbon steels (with or without Si or Pl. Finishing temperature (FT), gauge, and (particularly at the edges) coiling
temperature (CT) are the main influence factors with respect to scale thickness. Based on HTXRD oxidation trials and microscopic analy-
ses, trendlines are presented that roughly predict the final scale composition as a function of CT, for the coil centre and the edges. It ap-
pears that a CT of 400-600°C, in combination with a coil centre position, is favourable for decomposed wustite, which is the preferred com-
ponent for a good scale ad- and cohesion. Retention of wustite, the most preferred phase in the roll bite but very brittle at room tempera-
ture, is promoted by relatively high CTs (particularly with a coil quench) and by very low CTs. Hematite is formed at the edges in case of a
high CT. This extremely hard phase is unwanted at any stage.

Keywords: hot rolled steel strip, oxide scale, TGA, HTXRD.

Introduction M = J2. k p ' t (3)

During finishing rolling of hot rolled steel strip, tertiary which is actually the integrated form of the more funda-
oxide scale is developing. Its properties, depending on mental equation:
process conditions and steel chemistry, have a large impact
on events in the roll bite, and hence on surface quality.
Moreover, scale properties determine the processability of a
dM kp
= (4)
hot rolled coil in downstream processes like pickling, laser dt M
cutting, forming, stamping, or direct coating. Relevant
properties of the oxide layer are thickness, composition, Here k p is the parabolic rate constant.
structure, adhesion and cohesion. Although equations (3) and (4) are not valid for thin ox-
ide layers, when Fez+ diffusion is not yet rate-limiting, it is
Scale growth. The thickness of any oxide layer depends quite popular to assume simple parabolic growth kinetics
on the time-temperature cycle, rolling reduction scheme, al- from the start, since it is a relatively simple way to describe
loy composition and atmosphere conditions. When the ox- scale growth. This is allowable for long oxidation periods,
ide layer is still rather thin, the scale growth rate will either like in reheating furnaces, where the initial non-linear stage
be determined by gaseous transport of Oz towards the sur- can be neglected. However, also in papers dealing with rel-
face (or another oxidising species like HzO or COz), or by atively short oxidation time periods, like secondary and ter-
the chemical reaction itself. tiary scale growth in a hot strip mill, simple parabolic be-
In such a case, the scale growth rate dM/dt is independent haviour is frequently assumed. This is incorrect. As illus-
of scale thickness M as indicated in figure 1. This is de- trated in figure 1, simple parabolic kinetics imply scale
scribed by the linear rate equation [1, 2]:

(1) 20

::i 15
~
Here ki. is the linear rate constant. In integrated form •
(with kdT) = constant, i.e. under isothermal conditions I:
~ 10
within the time period t): ...
ii
~

M = «c t (2) •
5

When the oxide layer is rather thick, solid-state diffusion


of Fez+ will be rate-limiting. The Fez+ diffusion rate de- 30 60 90 120
creases with increasing scale thickness (i.e. diffusion dis- time (a.u.)

tance). This situation is commonly described by the well- Figure 1. Four types of scale growth kinetics (under isothermal con-
known simple parabolic rate equation [1, 2]: ditions).

steel research into 75 (2004) NO.6 399


Metal Forming - Hot Rolling

growth rates approaching infinity at t...(), which is physical- 0,3)


ly impossible. The mixed parabolic rate equation is a better
0,25
description of the oxidation kinetics, since it takes both the
linear and the parabolic stage into account [I, 2]: l;0,20
~

dM kp kp
i 0,15
LC steel with 0.4% Si,

II
at
- - --- with ex = - (5) humid air (15 vol%)
dt - M +ex k: 5°,10 -,
...............¢. ,,~ -.;

E i LC steel with l
0,05 l0.1% P, humid ~ Scale blistering
For M«a, equation (5) reduces to equation (1), and for lair (15 vol%)
~_ "' _
; .
1 paralinear kineticf
M»a, equation (5) reduces to equation (4). Figure 1 con-
120 240 360 600
firms that the relative difference in predicted scale thickness time (s)
between simple and mixed parabolic rate equations (with
the same kp ) becomes increasingly unimportant for large t Figure 2, TGA curves recorded during oxidation of low carbon
and M. At small t and M values, however, the simple para- steels at 1000°C in dry and humid air.
bolic rate equation becomes very inaccurate. Figure 1 also
illustrates a fourth type of oxidation kinetics, namely para-
linear kinetics. In some cases, it is found empirically that
the oxide layer is protective only up to a certain thickness scale formed in dry air. Apparently, scale constitution de-
M L. When ML is exceeded (M=M L+L1M), the extra scale 11M pends on humidity. This implies that laboratory oxidation
is non-protective. In such a case, transport of gaseous com- experiments performed with dry air have little predictive
ponents like O 2, H20 or CO 2 is possible through this sub- value for the humid conditions in a hot strip mill.
layer. As a result, the kinetics of further scale growth are de- - Scale growth is strongly temperature-dependent. This can
termined by Fe2+ diffusion through the part of the scale that be described by Arrhenius expressions,
is still protective, with thickness M L :
(7)
dM (8)
- = kc f at M > ML (6)
dt '
The influence of Si, P and humidity levels can be de-
Here kLj is the final linear rate constant; kLj < kL. scribed by expressions for kto. QL, kro. Qp and kLj as a func-
tion of these parameters. Parabolic activation energies Qp
TG A experiments range from 175.6 kl/mole for low-P steel to 197.6 kl/mole
(humid air) or 213.4 kl/mole (dry air) for high-P steel. The
Quantitative modelling of secondary and tertiary scale linear activation energy QL is 60.7 kl/mole for the base al-
growth on low-alloy steels implies assessment of numerical loy, but increases with increasing P and Si levels.
expressions for kp, kL, and possibly kLj as functions of tem-
perature and alloy composition. To this end, a series of ox- Tertiary scale thickness
idation experiments by thermal gravimetry anaysis (TGA)
were performed in a Cahn TG 171 thermobalance, at tem- Tertiary scale growth during finishing hot rolling can be
peratures between 700 and 12OO°C. Si and P had been iden- modelled with the obtained expressions, in combination
tified as the most important alloying elements affecting with the alloy composition, time-temperature cycle and
scale growth on low-alloy steels. Therefore, LC steel sam- rolling reduction scheme of the strip as indicated in
ples with Si levels up to 0.4 wt.% and P levels up to 0.1 figure 3.
wt.% were oxidised, in dry or humid air (0-35 vol.% H20 It should be pointed out that in this respect, surface tem-
vapour). Figure 2 shows a few examples of the large col- perature Tsurf is the relevant temperature. Tsurf can be sub-
lection of obtained TGA curves [3]. stantially below the average strip temperature, particularly
From the TGA experiments it appeared that: at and just after locations where the strip is cooled, i.e, dur-
- Scale growth is retarded by both Si and P (figure 2). This ing descaling, interstand cooling, and in contact with the
effect is relatively strong at lower oxidation temperatures. cooled work rolls.
- Paralinear kinetics were particularly observed with P-al- The most important parameters with respect to scale
loyed steels. This is associated with a tendency to form thickness at the exit side of the finishing train are fmishing
blisters and cracks within the scale, which makes the temperature (FT) and gauge. Further scale growth occurs on
scale partially non-protective (inset of figure 2). Indeed, the run-out table (ROT), depending on the amount of cool-
industrial P-alloyed hot rolled steels also show a poor ing applied, and thus on the coiling temperature (CT). How-
scale coherence, with a relatively high porosity and crack ever, the amount of scale grown on the ROT is modest since
level. temperatures are appreciably below the temperatures pre-
- Scale growth in humid air is significantly faster than in vailing upstream (Figure 4). The edges are somewhat cold-
dry air (figure 2). Moreover, the adherence of scale er than the strip centre, so up to the coiler, edge scales are
formed in humid air was significantly better than that of thinner than centre scales. This is unchanged after coiling at

400 steel research int. 75 (2004) No.6


Metal Forming - Hot Rolling

E 12
14 -------------------------1 LowCT High CT
• scale
formed
after
:a. coilling
-; 10 .scale
!
.!Ill
U
8
formed
on ROT
5 6
.!! escale
rJ 4 coller
formed
III during
2 rolling
centre edge centre edge
O¥'---.-----.,.-----,-----.---r----.,.----'
o 5 10 15 20 25 30
time (8) Figure 4. Schematic representation of the relative contribution of
process stages (finishing hot rolling, run-out table, and coil cooling)
to tertiary scale growth.
Figure 3. Calculated thickness of scale, developing in a hot strip fin-
ishing mill.

.~'-----'.

(a) . upper ' (b) i upper \

..:.... ..:....
i work 'I I work "
a low CT (roughly below 600°C). However, a substantial
amount of extra scale growth occurs at the edges after coil-
ing at a high CT (roughly above 650°C), due to air ingress
between the windings. As a result, edge scales are thicker Figure 5. a) Plastic deformation of scale in the roll bite (desired); b)
than centre scales at a high CT, figure 4. scale cracking (undesired).
The final scale thickness is relevant for throughput and
mass balance of pickling lines. Moreover, thin scales can
generally withstand higher loads than thick scales before
failure (cracking) occurs. This is of importance for the ad- formable than hot scales. Therefore, strip cooling (during
hesive and cohesive properties of the final scale on unpick- descaling and interstand cooling) should be carefully bal-
led hot rolled strip. anced. Too much cooling at the wrong moment causes over-
chilling of the scale, whereas insufficient cooling leads to
Scale in the roll bite high surface temperatures, and thus excessive scale growth.
Moreover, surface temperatures above 950°C affect the
This also applies to the intermediate scale thickness, dur- scale composition adversely. For the events in the roll bite,
ing rolling reductions. Figure 3 clearly shows that the oxide scale composition is even more important than scale thick-
layers entering the first three finishing stands, FI-F3, are ness.
usually considerably thicker than the final scales. The scale
at these intermediate stages should not be too thick, other- Scale composition
wise the scale is cracked in the roll bite, rather than plasti-
cally deformed, which results in a poor surface quality, Three different iron oxide phases can be found in the
figure S. scale, namely Fel_xO (wustite), Fe304 (magnetite) and
Whether Figure 5a or 5b prevails does not only depend on FeZ03 (hematite). Table 1 lists some properties of these ox-
the incoming scale thickness and the rolling reduction. ides. In particular wustite has some extraordinary features.
Scale temperature at the entry of a roll bite is also an im- Firstly, it has an extremely broad composition range; x val-
portant factor, since relatively cold scales are less de- ues in Fel_xO range from 0.04 to 0.17. Secondly, wustite is

Table 1. Components in oxide scales, and some of their properties.

Hot I) Tensile Effect on


Vickers Strength 2) Pickling
Name Formula Fe/O ratio scale
Deformability Hardness 2) rate
(MPa) lntearity 2)
Hematite Fe201 0.67 bad ± 1000 10 bad very slow
Magnetite Fe104 0.75 fair ±550 40 fair slow
Wustite Fe1_xO 0.83 - 0.96 good ±300 0.4 bad fast
Decomposed
Fe304 + a-Fe 0.83 - 0.96 N.A. ± 550 >40 good slow
lWustite
I) under hoi rolling conditions 2) at room temperature

steel research into 75 (2004) No.6 401


Metal Forming - Hot Roiling

thermodynamically unstable below 570°C. During cooling, Of course, step 4 was by far the most time-consuming
reaction (9) occurs, yielding "decomposed wustite"; i.e. a step, whereas step 3, the actual oxidation step, was relative-
mixture of finely distributed a-Fe particles in a magnetite ly short. HTXRD diffractograms were recorded during
matrix: these steps (and in some cases also at the end of step 2), ini-
tially at a high frequency (1-3 per minute), then at lower fre-
(9) quencies (1-6 per hour). A large series of HTXRD experi-
ments was carried out to investigate the influence of simu-
In many cases, less than 100% of the wustite is trans- lated FT, CT, position within the coil (centre versus near-
formed following reaction (9); therefore retained wustite is edge region), and coil cooling conditions (water-quench
often observed in oxide scales at room temperature. versus unforced cooling). Figure 6a shows an example of a
At hot rolling temperatures, wustite exhibits a remarkably series of HTXRD patterns recorded during an experiment
high plasticity, but wustite is extremely brittle at room tem- with simulated FT=760°C, CT=620°C, coil centre, un-
perature. So wustite is the desired oxide phase during quenched. For comparison, figures 6b and 6c show the ef-
rolling, but high fractions of retained wustite in the cold coil fects of coil quenching, and of a rather low coiling temper-
are detrimental to the cohesion of the scale. ature of 380°C, respectively.
Hematite is brittle and extremely hard, and therefore un-
desirable at any stage of the process route. In the roll bite,
hematite causes excessive roll wear and a bad strip surface
quality. 40 42 44 46 48 50
Magnetite, with an intermediate Fe/O ratio and an inter- (8)
mediate hardness, shows some plasticity at hot rolling tem- FT=760'C
CT=620'C
peratures. Therefore, a certain fraction of magnetite can be coilcentre
tolerated during rolling reductions. At room temperature, noquench
magnetite is the least brittle iron oxide phase, which is pos-
itive with respect to scale integrity. However, an extensive
series of laboratory tests [4] has shown that the best scale
integrity occurs with oxide layers that largely exist of de-
composed wustite. For such scales, the test results are sub-
stantially better than for samples with predominantly com-
40 42 44 46 48 50
pact magnetite. Presumably, the toughness of the magnetite dll'rnlctlon angle (0 28)
matrix is enhanced by the presence of numerous tiny a-Fe 40 42 44 46 48 50
particles, and so is its resistance to cohesive failure. (b)
Moreover, the a-Fe particles precipitating near the scale- FT=760'C
steel interface connect to the steel base. Looking at sub-mi- CT=620'C
coilcentre
cron scale, this leads to a very rough interface, and conse- with quench
quently also to an increased resistance to adhesive failure of
the oxide scale.

HTXRD experiments
High Temperature X-Ray Diffraction (HTXRD) was used
40 42 44 46 48 50
to monitor the composition of scale in situ during simulat- dll'rnlctlon angle (" 28)
ed hot rolling and coil cooling conditions. Each HTXRD- 40 42 44 46 48 50
experiment comprised the following steps: (e)
1. A cold rolled Ti,Nb-IF steel strip (1ooxlOxl mm) was FT=760'C .
CT=380'C .
placed in Philips X'pert MPD diffractometer, equipped coilcentre
with a filtered Co-K, radiation source, a Raytech 12° po- noquench
sition sensitive detector (PSD) and an Anton Paar
HTK2000 heating stage.
i
2. The sample was heated in a Nz flow to a chosen simulat-
ed hot rolling temperature.
3. The sample was oxidised in a humid air flow (dewpoint
f
+20°C), while subjected to a time-temperature-cycle sim-
40 42 44 46 48 50
ulating finishing hot rolling and ROT cooling, to a simu- dll'rnlctlon angle (0 28)
lated CT.
4. The sample was slowly cooled down in a simulated coil
Figure 6. Examples of series of HTXRD patterns recorded during
cooling time-temperature cycle. A N z flow was supplied experiments simulating ferritic finishing rolling at 760°C, coiling at
when the centre of a coil was simulated, and a 620 or 380°C, and subsequent coil cooling (centre position).
99%Oz/1 %N z flow when cooling of a near-edge region a) CT=620°C, no quench. b) CT=620°C, quench simulated, 1h after
was simulated. coiling. c) CT=380°C, no quench.

402 steel research into 75 (2004) No.6


Metal Forming - Hot Rolling

From the HTXRD experiments the following conclusions Trendlines for scale composition
could be derived:
- When tertiary scale starts to grow (after secondary Figure 7 shows trend-lines of the scale composition as a
descaling), first only wustite is present. This is very ben- function of the coiling temperature, for the coil centre (top
eficial with respect to the deformability in the roll bite, diagram) and the coil edges (bottom diagram). These trend-
and probably the main reason why a good surface quality lines could be drafted on the basis of the HTXRD trials and
on hot rolled strip is possible anyway. It takes some time a large set of microscopy analysis results of scale on hot
before magnetite starts to develop, but once this has hap- rolled steels [4]. The strip head or tails can be regarded as a
pened, the fraction of magnetite increases rapidly, so that special case of an edge.
the scale consists of substantial fractions of both wustite Figure 7 may only be used for rough estimations of scale
and magnetite at the end of the ROT. Normally there is no compositions, as secondary influence factors are not taken
time to develop hematite up to this stage, except when the into account (such as alloy composition, mill layout, rolling
rolling speed is rather low (thick gauges) in combination speeds, FT, interstand and ROT cooling practice).
with relatively high FTs and CTs, or blisters or cracks oc-
cur in the scale (e.g. during a rolling pass), resulting in Scale on commercial hot rolled strips
parts of the scale being cut off from the flux of outward-
ly diffusing ferrous ions. Wustite in these scale parts is Empirically observed scale thicknesses and micro-struc-
rapidly oxidised to magnetite and eventually hematite. tures can be better understood with the insights outlined
above. Figure 8 shows some examples. Figure 8a shows
- Immediately after coiling at a high temperature
the typical double-layered microstructure of scale on hot
(CT>600°C; e.g. Fig. 6a and 6b), Fe diffuses from the
rolled Dual Phase (DP) steel. Due. to the very low CT of
steel base into the scale. This leads to conversion of mag-
these steels (CT<200°C), no changes occur after coiling;
netite into wustite, and transformation of a-rich wustite
the scale structure is the same as at the end ofthe ROT. The
into a more Fe-rich type of wustite. The rates of these
scale has an inner layer of retained wustite, which gives the
(diffusion-controlled) processes increase with (coiling)
scale a low cohesive strength, and an outer layer of compact
temperature. Near the edges, these processes are counter-
magnetite. The pickling rate of such a double-layered scale
acted by the influence of air ingress between the coil
can be strongly enhanced by creation of cracks in the scale
windings in combination with a faster temperature decay.
by a tension leveller, since the inner layer is much easier to
- Wustite decomposition into magnetite and ferrite, accord-
ing to reaction (9), proceeds rather slowly just below
570°C, accelerates with decreasing temperature, and be-
100
comes very fast around 400°C. When temperature is fur-
90
ther lowered, reaction (9) slows down, but does not stop e 80
until the temperature is below 300°C. i
.....
0: 70

- No wustite can be retained when a strip is coiled in the


most critical temperature region around 400°C. Wustite
.
E 80
II
50

retention is possible in two cases: either with a very low ]


.
'l5
40

30
coiling temperature (e.g. with hot rolled Dual Phase 0: 20
e
steels, which are coiled below 200°C), or with relatively W 10
01:
high coiling temperatures (compare Figures 6a and 6c). 0
100 200 300 400 500 600 700 600
- After coiling at a high coiling temperature (CT>700°C), Coiling temperature rq
more wustite is retained than with somewhat lower coil-
ing temperatures (e.g. 600-700°C), because the decompo- I coll.dges I l
sition kinetics of Fe-rich wustite are considerably slower
than those of a-rich wustite. The occurrence of wustite
crystals with varying Fe/Ocratios was evidenced by
wustite diffraction peak splitting and/or shifting during
HTXRD experiments.
- Wustite retention is strongly enhanced by coil quenching
after coiling at high temperatures. In contrast, quenching
has little or no effect on scale composition if CT<600°C.
- Substantial amounts of hematite are formed near the
__ hemalite _ compact magnelde
edges of coils coiled at high temperatures (CT> 500°C).
-&-decomposed wOstile - no quench - : - retained wOstile - no quench
In summary, coiling temperature and position within the __ decomposed wOstile - quenched coil __ retained wOstite·quenched coil

coil have been identified as the primary influence factors


with respect to the final composition of tertiary scale. For Figure 7. Trend-lines giving a rough indication of scale composition
high CT's, coil quenching significantly affects scale com- as a function of coiling temperature. Top: coil centre. Bottom: coil
position, compared to natural coil cooling in air. edges.

steel research into 75 (2004) No.6 403


Metal Forming - Hot Rolling

pickle than the outer layer. The scale structure at the edges Concluding remarks
is the same as at the strip centre. However, the inner wustite
layer is thinner at the edges than it is at the centre. This also A consistently good surface quality and downstream
applies to the total scale thickness, as expected from the low processability of hot rolled strips requires control of tertiary
CT (4.5 urn versus 5.5 urn for this particular coil). scale properties throughout the whole process route be-
The scale shown in figure 8b largely consists of decom- tween secondary descaling and coil cooling to room tem-
posed wustite, and some areas of compact magnetite, due to perature.
the coiling temperature of 450°C, which favours complete In this respect, scale composition is more important than
wustite decomposition. This appeared to be beneficial for a scale thickness.
good scale integrity. The scale is slightly thicker (6 urn) Finishing temperature (Fl') is the main parameter deter-
than in figure 8a (5.5 urn) due to the somewhat higher Fr. mining the final scale thickness at the strip centre, followed
Figures 8c and 8d present the microstructures of centre by gauge and coiling temperature (CT). At the edges, CT is
and edge scale, respectively, on a coil that was quenched in more important.
a water basin, after coiling at a rather high temperature
In the roll bite, wustite is the preferred component. Fur-
(CT=75I "C). A large fraction of retained wustite is present
thermore, too thick or over-chilled oxide layers should be
at the centre of this coil (figure 8c), due to the combination
avoided to prevent scale cracking. Therefore strip cooling
of quenching and a high CT. In contrast, the near-edge re-
should be carefully balanced.
gion shows an outer rim of hematite, a thick layer of com-
At room temperature, decomposed wustite is the pre-
pact magnetite, and some decomposed wustite near the in-
ferred component for a good scale integrity.
terface (figure 8d). Obviously, the edges severely suffered
Scale integrity at the coil edges is generally significantly
further oxidation after coiling. Note that the edge scale is
inferior to that at the coil centre, due to lower fractions of
relatively thick (-10 urn) due to the high CT, whereas the
decomposed wustite at the edges and, in case of a high CT,
centre scale is much thinner (-6 urn) due to the low Fr.
significant Fez03 formation.
From table I it can be understood why this hot rolled strip
exhibits a rather bad scale integrity over the whole strip Very low or very high CTs are detrimental to scale in-
width. At the centre, this is due to the high fraction of re- tegrity, due to high fractions of retained wustite. This is fur-
tained wustite, and at the edges due to the subtantial ther aggravated by quenching, after coiling at a high CT.
amounts of hematite and compact magnetite. This is aggra- For the coil centres, there seems to be a broad optimum
vated by the thickness. However, the edge scale is much CT range around 550°C. For the coil edges, the optimum is
more difficult to pickle than the centre scale, due to these much narrower, at an inferior level, and shifted to a lower
differences in scale structure and thickness. temperature.

Acknowledgement

Parts of the presented research were financially support-


ed by the ECSC.
(A2004024; presented in Dusseldorf on 17 June 2003)

Contact: Dr. P. Henk Bolt


Corus Research, Development & Technology
P.O. Box 10000
1970 CA JJmuiden, The Netherlands

References
[I] U.R. Evans: Reviews of Pure and Applied Chemistry. 5 (1955), No.1,
1/21.
[2] U.R. Evans: "Velocity of film growth" in: The Corrosion and Oxida-
tion of Metals: Scientific Principles and Practical Applications, E.
Arnold Publishers Ltd., London, 1960, Chapter XX, p. 819/59.
[3] H.F. Marston, R. Ratcliffe, P.H. Bolt, M. van Lankveld, V. Lanteri, G.
Leprince, M. Jarl, J. Niska, R. Klima, M. ROder: "Oxidation and De-
carburisation of High Carbon, Special and General Steels", ECSC re-
search project 721O.PR/019, Final Report EUR 20497, 2002.
Figure 8. Examples of optical microscopy images of scale on vari- [4] H. Bolt, G. Bourdon, X. Cornet, S. Ehlers, F. Friedel and F. Steinert:
ous hot rolled steels (etching: 0.5% HCI). a) Dual Phase steel, "Investigation of the Formation, Constitution and Properties of Scale
FT=850°C, CT=150°C, strip centre. b) Low carbon steel, FT=875°C, Formed during the Finishing Rolling, Cooling and Coiling of Thin Hot
CT=450°C, strip centre. c) Low carbon steel, FT=773°C, Strips", ECSC Research Project 721O.PR/153, Draft Final Report,
CT=751DC, coil quenched, strip centre. d) same coil, strip edge. 2003.

404 steel research int. 75 (2004) No.6

You might also like